Mandrel

ABSTRACT

A mandrel suitable for supporting and unwinding a convolutely wound web material is disclosed. The mandrel has a mandrel shaft with a longitudinal axis, a plurality of mandrel arms extending from the mandrel shaft, and at least one expansion element disposed upon a respective each of the mandrel arms. The mandrel shaft is capable of rotating about the longitudinal axis. Each of the mandrel arms is disposed and rotatable about the longitudinal axis. The at least one expansion element is expandable radially away from the respective mandrel arm relative to the longitudinal axis. The convolutely wound web material is disposable about each of the mandrel arms. Further, the at least one expansion element is expandable into contacting and releasable engagement with the convolutely wound web material. The convolutely wound web material is fixably and releasably disposed about each of the mandrel arms.

FIELD OF THE INVENTION

The present disclosure relates generally to an apparatus for moving andsupporting web material, such as polyethylene into a web consumingapparatus such as a converter for manufacturing disposable absorbentarticles. The present disclosure more particularly relates to the use ofan improved mandrel for loading, unloading, supporting, and/or unwindingconvolutley wound rolls of web materials for producing diapers andcatamenial devices.

BACKGROUND OF THE INVENTION

In order to continuously supply a web consuming apparatus with web froma succession of rolls of web material each new roll must be spliced tothe preceding roll. Desirably, this is done without diminishing the rateof forwarding web to the web consuming apparatus. As such, a continuoussupply of convolutely wound rolls of web material must be supplied tothe apparatus in order to maintain manufacturing speeds.

Today, in most manufacturing site, manual operation remains the mostcommon for material handling & delivery. In most operations, theassembled products materials are processed on-line as webs and a vastmajority of these web materials are brought to the line as planetaryrolls of convolutely wound rolls of web material.

It will also be appreciated that raw material handling accounts for30-50% of operational tasks across an assembled products manufacturingline today. This includes delivery, staging, roll preparation, andloading. Additionally, increasing line speeds increases the frequency ofroll changes and drives higher operational efforts. In short, the manualloading of roll materials into an assembled products line is often foundto be cost prohibitive.

Further, the floor space necessary today for unwind stands and rawmaterial staging is roughly equal to the space necessary for theplacement of an assembled goods converting operation. Additionally,future innovation tends to bring more complex assembled goods productsand requires significantly more web materials. This confounds currentmanufacturing operations as floor space is likely fully used already.Thus, finding additional floor space to accommodate both the existingassembled products lines and the expanded requirements to accommodatethese additional lines is problematic.

Some solutions to this issue have been to utilize additional floor spaceto incorporate automation solutions. But seemingly, floor space is at apremium. However, current automation solutions provide significantsafety concerns due to the increased risk of human injury or equipmentdamage. Others have provided additional equipment formats such asfestooning, traversing wound rolls, and the like to extend roll life andreduce manual effort required to load such materials. However, thesesolutions only work for a limited range of materials.

Net—there is a compelling need to eliminate the manual effort requiredto stage, prepare, load, and thread up web materials to feed theconverting equipment to manufacture assembled goods such as catamenialdevices and diapers. There is a compelling need to reduce the floorspace required for material staging, preparation, loading, and unwindconvolutely wound materials, inclusive of automation. Further, there isa compelling need to enable a ‘lights-out’ web material supply solutionthat is nearly capital equal to current unwind operations. Additionally,there is a compelling need to support agile manufacturing principles onconverting lines that enable easy reconfigurability. Thus, it would bebeneficial to solve these challenges of footprint, effort, and costsimultaneously. The present description solves these challenges.

SUMMARY OF THE INVENTION

The present disclosure provides for a mandrel suitable for supportingand unwinding a convolutely wound web material where a portion of theconvolutely wound web material forms a hollow core therein. The mandrelcomprises a mandrel shaft having a longitudinal axis, a plurality ofmandrel arms extending from the mandrel shaft, and at least oneexpansion element disposed upon a respective each of the mandrel arms.The mandrel shaft is capable of rotating about the longitudinal axis.Each of the mandrel arms is disposed and rotatable about thelongitudinal axis. The at least one expansion element is expandableradially away from the respective mandrel arm relative to thelongitudinal axis. The core of the convolutely wound web material isdisposable about each of the mandrel arms. Further, the at least oneexpansion element is expandable into contacting and releasableengagement with the portion of the convolutely wound web materialforming the hollow core. The convolutely wound web material is fixablyand releasably disposed about each of the mandrel arms.

The present disclosure also provides for an end effector for a robot.The end effector comprises a mandrel shaft having a longitudinal axis, aplurality of mandrel arms extending from the mandrel shaft, and at leastone expansion element disposed upon a respective each of the mandrelarms. The mandrel shaft is capable of rotating about a longitudinalaxis. Each of the mandrel arms is disposed and rotatable about thelongitudinal axis. The at least one expansion element is expandableradially away from the respective mandrel arm relative to thelongitudinal axis.

The present disclosure also provides for a mandrel arm for a mandrel.The mandrel arm comprises at least one expansion element disposed upon asurface of the mandrel arm. The at least one expansion element isexpandable radially away from the surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary improved unwind standshowing according to the present disclosure;

FIG. 2 is a perspective view of the exemplary improved unwind standshowing the positionable roll grasping apparatus in the form of a robotengaging a convolutely wound roll of web material that is to be loadedonto a mandrel of the unwind stand;

FIG. 3 is a perspective view of the exemplary improved unwind standshowing the positionable roll grasping apparatus in the form of a robotengaging a convolutely wound roll of web material onto a mandrel of theunwind stand;

FIG. 4 is a perspective view of the exemplary improved unwind standshowing the positionable roll grasping apparatus in the form of a robotengaging the core remaining from a spent convolutely wound roll of webmaterial disposed upon a mandrel of the unwind stand;

FIG. 5 is a perspective view of the exemplary improved unwind standshowing the positionable roll grasping apparatus in the form of a robotremoving the core remaining from a spent convolutely wound roll of webmaterial disposed upon a mandrel of the unwind stand;

FIG. 6 is a perspective view of the exemplary improved unwind standshowing the positionable roll grasping apparatus in the form of a robotengaging a convolutely wound roll of web material onto an empty mandrelof the unwind stand;

FIG. 7 is a perspective view cross-sectional view of the of theexemplary improved unwind stand of FIG. 5;

FIG. 8 is a perspective view of an alternative embodiment of exemplaryimproved unwind stand showing according to the present disclosureshowing a positionable roll grasping apparatus in the form of a robotdisposed integrally with the frame and the first and second latticedisposed above the rolls of convolutely wound web material;

FIG. 9 is a perspective view of an alternative embodiment of exemplaryimproved unwind stand showing according to the present disclosureshowing a positionable roll grasping apparatus in the form of a robotdisposed integrally with the frame and the first and second latticedisposed below the rolls of convolutely wound web material;

FIG. 9 is a perspective view of an alternative embodiment of exemplaryimproved unwind stand showing according to the present disclosureshowing a positionable roll grasping apparatus in the form of a robotdisposed integrally with the frame and the first and second latticedisposed below the rolls of convolutely wound web material;

FIG. 10 is a perspective view of an alternative embodiment of exemplaryimproved unwind stand showing according to the present disclosureshowing a positionable roll grasping apparatus in the form of a robotdisposed integrally with the frame and the first and second latticedisposed adjacent the rolls of convolutely wound web material;

FIG. 11 is a perspective view of an exemplary end effector suitable foruse with a positionable roll grasping apparatus in the form of a robotof the disclosed unwind stand;

FIG. 12 is an elevational view of the exemplary end effector of FIG. 11;

FIG. 13 is a cross-sectional view of the exemplary end effector of FIG.11;

FIG. 14 is a perspective view of another exemplary end effector inproximate contact with a second end effector;

FIG. 15 is a perspective view of the exemplary end effectors of FIG. 14in interleaved and contacting engagement;

FIG. 16 is a perspective view an exemplary robot and end effector in theform of a mandrel assuming contacting engagement with the hollow coreportion of a web material;

FIG. 17 is a perspective view of the robot of FIG. 16 transporting theweb material into eventual contacting and mating engagement with anempty mandrel disposed upon an exemplary unwind stand;

FIG. 18 is a perspective view of the robot of FIG. 16 disposing the webmaterial into contacting and mating engagement with an empty mandreldisposed upon the unwind stand;

FIG. 19 is a perspective view of the positionable roll graspingapparatus in the form of a robot of FIG. 16 disengaging the end effectorfrom the second web material; and,

FIG. 20 is a perspective view of the robot of FIG. 16 completelydisengaged from the second web material and ready for a new or differenttask.

DETAILED DESCRIPTION

As will be described in detail, the improved unwind stand 10 describedherein may simultaneously deliver a plurality of web materials todownstream manufacturing equipment. As is to be appreciated, multipleimproved unwind stands 10 described herein can be configured to allsimultaneously supply web material to a single downstream manufacturingprocess and/or a plurality of downstream manufacturing processes. Theimproved unwind stand 10 described herein may be positioned in amanufacturing environment proximate to other manufacturing apparatuses.While no particular downstream equipment is shown, it will be understoodthat the continuous webs of web material supplied by the improved unwindstand 10 could be advanced to a variety of web material handlingprocesses, including without being limiting, laminating operations,printers, embossing operations, slitting, folding and cuttingoperations, converting operations, and combinations of these.

One embodiment of the improved unwind stand 10 is illustrated in FIGS.1-7. FIGS. 1-6 are perspective views of the improved unwind stand 10 inaccordance with one non-limiting embodiment. FIG. 7 is a cross-sectionalview of the improved unwind stand 10 in accordance with one non-limitingembodiment. The improved unwind stand 10 is provided with a frame 12.The frame 12 includes various components, such as structural supportsand plates. For example, the frame 12 may include a plurality offaceplates 14. The faceplates 14 may be fastened to a support member 16of the frame 12, for example. The frame 12 may include at least onecross-support member 18. The frame 12 can be provided as generallysectional, with three sections 20 a, 20 b, and 20 c. It would beappreciated by one of skill in the art that other embodiments maycomprise more or less sections. Furthermore, the sections may bearranged horizontally (as illustrated) or in a vertically arrangement,or a combination of both. The improved unwind stand 10 may bemanufactured from any suitable materials, such as steel, stainlesssteel, aluminum or composite materials, for example. The improved unwindstand 10 may also be assembled or constructed using any suitabletechniques, such as welding, rivets, adhesives, or screws, for example.

The improved unwind stand 10 may include a plurality of feet 22 arrangedproximate the bottom side. As will be appreciated, the plurality of feet22 may be adjustable in order to adjust the elevation of the improvedunwind stand 10. The improved unwind stand 10 may allow for transport ofan improved unwind stand 10. Furthermore, the improved unwind stand 10may comprise a cable tray for housing various power and communicationcables. Other techniques may be used for housing the cables, such asconduits, for example.

As shown, the improved unwind stand 10 is generally rectangular. Invarious embodiments, other configurations may be used, such as a cubeshape or a triangular shape, for example. The improved unwind stand 10may have a plurality of faces, including a first face 26 and a secondface 28. As illustrated, the first face 26 and the second face 28 may belaterally opposed and separated by a distance D. In various embodiments,distance D may be in the range of about 3 feet to 8 feet or less. Acavity 30 may be defined intermediate the first face 26 and the secondface 28. As shown, while the cavity 30 is illustrated as being generallyrectangular, it is to be appreciated that the cavity 30 may be a varietyof shapes and may largely depend on the relationship of the variousfaces. For example, if the frame 12 is triangular, the cavity 30 may begenerally triangular as well. The cavity 30 may be generally enclosed bythe various plates 14 of the improved unwind stand 10. In order toprovide access to components and equipment within the cavity 30, theimproved unwind stand 10 may have at least one cavity access port.Furthermore, a door may be mounted in the cavity access port to controlaccess to the cavity 30. It is preferred that any door be sized to allowa person to enter the cavity 30. Various embodiments may comprise aplurality of doors and a plurality of cavity access ports.

The improved unwind stand 10 may comprise a plurality of mandrels 40 a,40 b, 40 c, 40 d, 40 e, 40 f extending from a face of the improvedunwind stand 10, such as the first face 26. The mandrels 40 a, 40 b, 40c, 40 d, 40 e, 40 f may extend generally perpendicular to the first face26, or may be positioned at any other suitable angle. In someembodiments, the improved unwind stand 10 includes a first splicer 42,and some embodiments may also include a second splicer 44. The firstsplicer 42 and the second splicer 44 may be positioned on the improvedunwind stand 10 in any suitable location, such as in between a pair ofmandrels. As illustrated in FIG. 4, the first splicer 42 may beconfigured to receive a web material 46 and a web material 48.Similarly, the second splicer 44 may be configured to receive a webmaterial 46 and a web material 48.

The improved unwind stand 10 may further comprise a first dancer 50,and, if needed, a second dancer 52. The first dancer 50 may comprise anarm 54 that is mounted to the frame 12. The first dancer 50 may alsocomprise a first lattice 62. The first lattice 62 may comprise aplurality of rollers 64 and a complimentary plurality of rollers 66mounted to the frame 12. As is to be appreciated, the number of rollers64, 66 in the first lattice 62 may vary depending on the type of webmaterial being fed through the first lattice 62 and the feed speed ofthe web material 46, 48. The second dancer 52 may have similarcomponents. Similar to the first dancer 50, the second dancer 52 maycomprise a second lattice 72 comprises a plurality of rollers 74 and aplurality of rollers 76 mounted to the frame 12. The number of rollersin the first lattice 62 may differ from the number of rollers in thesecond lattice 72, as the number of rollers used is based oncharacteristics of the web material being fed through the lattices 62,72, such as web material 46, 48.

In some embodiments, the improved unwind stand 10 may comprise a firstand second metering rolls. The first and second metering rolls may bedriven by an actuator to establish a line speed and/or line tension ofthe web material. The improved unwind stand 10 may further comprise aplurality of mandrels 40 (also known as “spindles”) and/or idler rollersto engage and direct the web material. As is to be appreciated, thevarious spindles may rotate relative or may be fixed. The variousmandrels 40, spindles, and metering rolls may be powered by any motiveforce known in the art, collectively referred to herein as “actuators.”Power sources include, without being limiting, standard and servoelectric motors, air motors, and hydraulic motors. The power source maybe coupled to any rotating components of the improved unwind stand 10 byany power transfer means known in the art, such as direct coupling theactuator to the rotating component, driving the rotating componentthrough the use of chains and sprockets, belts and sheaves, and gearing,for example.

In one embodiment, the actuators can be operably engaged to each mandrel40 a, 40 b, 40 c, 40 d. In other embodiments, however, a single actuatormay be used to drive a plurality of mandrels. The actuators may extendinto the cavity 30 of the improved unwind stand 10. Various power andcommunication cables may be attached to the actuators inside the cavity30.

In one embodiment, a roll 100 of the first web material 46 maybe mountedon the mandrel 40 a. The roll 100 may be rotatable in either a clockwiseand/or counter clockwise direction. The web material 46 may be unwoundfrom the roll 100 and fed into and pass through the splicer 42. Oncepassing through the splicer 42, the web material 46 may enter the firstlattice 62. As illustrated, the web material 46 may be looped over aroller 66 and then extend to a roller 64. The web material 46 may thenextend between a series of complimentary rollers in the first lattice 62thereby forming a “festoon.”

As will be appreciated upon consideration of this disclosure, when thearm moves (or pivots) the distance between the rollers 64 and therollers 66 increases, thereby increasing the linear amount of the webmaterial 46 engaged in the first lattice 62. Additionally, the number ofrollers 64, 66 used in the first lattice 62 will also determine thelinear amount of the web material 46 engaged in the first lattice 62.After passing through the first lattice 62, the web material 46 mayproceed in the machine direction towards the first metering roll. Afterengaging with first metering roll, the web material 46 may be directedtoward downstream equipment.

A roll 104 of the web material 48 maybe mounted to the mandrel 40 b. Theroll 104 may be configured to rotate in a clockwise and/orcounterclockwise direction. In the illustrated embodiment, the roll 104serves as a stand-by roll for the splicer 42, and therefore the webmaterial 48 may be the same type of the web material as 46. In someembodiments, it may be advantageous to provide web material 48 as adifferent web material that web material 46 in order to allow for theability to rapidly change web material types without having to actuallyremove the given web material before changing over to different productconstructions. In other embodiments, however, the roll 104 may bypassthe splicer 42 and/or may be a different web material than web material46. As used herein, splicing (and splicing means) refers to any processof joining, or any apparatus or equipment associated with or necessaryto join, a first web material to a second web material, such as joiningthe web material 46 from roll 100 to the web material 48 from the roll104. As used herein, a splice is considered to be the combined localizedportions of a first web material and a second web material that arejoined together.

Web material 46, 48 that may be spliced (with splicing means) caninclude, without being limiting, non-woven materials, paper websincluding tissue, towel and other grades of paper, absorbent materials,plastic films and metal films. The splicer 42 may be adapted to splicethe web material of any suitable width and thickness. Web materialranging in width from a few millimeters to about several meters may beprocessed by an appropriately sized splicing apparatus. Similarly, webmaterial ranging in thickness from a few thousandths of a millimeter toseveral millimeters may be spliced by an appropriately adapted splicer42.

It should be understood that first and second web materials 46, 48, suchas thermoplastic material, can be added to the line operation in analternating fashion in the above described manner whenever a low rollamount is detected, thereby allowing the line to run continuously. Itshould also be understood that while the method and apparatus of thepresent invention have been described with reference to first and secondweb materials, it is intended that multiple rolls of web materials willbe spliced together over time to keep the line running. Further, it iscontemplated that the first and second web materials need not be madefrom the same web material as long as the web materials used for thefirst and second webs are compatible from a splicing standpoint. Due tothe ability to continuously run the line operation according to theteachings of the present invention, products can be manufactured withminimal manufacturing down-time.

First and second lattices may serve has accumulators during a zero-speedsplice and may also serve as part of the first and second dancers 50, 52to alter the line tension of the web materials 46, 48. As is to beappreciated, the improved unwind stand 10 may comprise a variety ofsensors to determine roll diameter and material tension for example. Acontroller, or plurality of controllers, may be used to receive variousinputs from the sensors on manufacturing line and the improved unwindstand 10 and make adjustments as needed in a continuous and ongoingfashion. Additional detailed descriptions of various types controlmethods and apparatii can be found in U.S. Pat. Nos. 6,991,144 and7,028,940 incorporated by reference herein.

First and second web materials 46, 48 can be provided to the improvedunwind stand 10 through means known to those of skill in the art. Forexample, as shown, first and second web materials 46, 48 can be providedto the improved unwind stand 10 through the use of carts 110. By way ofexample only, carts 110 can be provided with a quantity of convolutelywound rolls of web material 120 suitable for use as first and second webmaterials 46, 48.

During operation, the splicer 42 may perform a zero-speed splice of atail end of the web material 46 on roll 100 to the beginning end of theweb material 48 on roll 104 while simultaneously continuing to deliverthe web material 46 to the downstream equipment. During a splicingoperation, the arm 54 may move in order to serve as an accumulator andincrease the linear amount of the web material 46 engaged in the firstlattice 62. When the roll 100 stops spinning, the arm moves or pivotsand the web material 46 is drawn out of the first lattice 62 to supplythe downstream equipment. Therefore, the splicer 42 may splice the webmaterial 46 to the web material 48 while the rolls are stopped, yet theweb material 46 continues to be delivered from the improved unwind stand10 to downstream equipment without disruption. Once the splice has beenperformed, the mandrel 40 b may be rotated by an actuator to unwind theweb material 48 from the roll 104. As will be appreciated, once the webmaterial 48 is unwinding from the roll 104 and supplying web material tothe downstream equipment, a replacement roll may be loaded onto mandrel40 a, with material from that replacement roll fed into the splicer 42and positioned to serve as a standby roll.

The splice between the web material 46 and the web material 48 may beaccomplished by any means known in the art. The nature of the splice maybe related to the nature of the particular web material being spliced.In one embodiment two web materials 46, 48 can be spliced together byusing two-sided splicing tape having adhesive on each side of the tape.In this embodiment, the two-sided splicing tape is affixed first to oneweb material 46 and then to a second web material 48. Pressure may beapplied to the portion of the two web materials 46, 48 after theapplication of the two-sided splicing tape. In another embodiment twoweb materials 46, 48 may be joined by applying an adhesive directly toone web material 46 and then bringing the second web material 48 intocontact with the adhesive. Pressure may be applied to the two webmaterials 46, 48 at the location of the adhesive to assist in thejoining of the web materials 46, 48.

In another embodiment two web materials 46, 48 may be brought into aface-to-face relationship and then subjected to sufficient pressure tobond the two web materials 46, 48 together. In this embodiment, the twoweb materials 46, 48 may be subjected to sufficient pressure to glassinethe two web materials 46, 48 creating a bond sufficient to withstand theprocess tension applied to the spliced web material.

In another embodiment the two web materials 46, 48 may be brought into aface to face relationship and exposed to a bonding means. Bonding meansinclude without being limiting, exposure to infra-red or otherelectromagnetic radiation to heat and fuse the web materials 46, 48,ultrasonic energy applied from an appropriately adapted ultrasonic hornto the combined web material against an anvil to heat and fuse the webmaterials 46, 48 together, and the spray application of a solvent tofuse the web materials 46, 48.

In one embodiment, the improved unwind stand 10 may support additionalrolls, such as additional roll 112. In various embodiments, additionalroll 112 may be configured to operate substantially similar to rolls100, 104. For instance, additional roll 112 may serve as a supply rollor as a stand-by roll. While rolls 100, 104, 112, 120 are shown, it isto be appreciated that more or less rolls may be used in variousembodiments. For example, some embodiments of the improved unwind stand10 may include additional vertical sections to accommodate an additionalroll or additional rolls. Furthermore, in various embodiments, theimproved unwind stand 10 may include mandrels on other faces that areconfigured to receive rolls of web material. In one embodiment, thesecond face 28 may comprise a set of mandrels. Rolls of web material maybe mounted on these mandrels and during operation downstream equipmentmay be continuously fed with web material from at least one of therolls. It is to be appreciated that in some embodiments the second face28 of vertical section 20 c may comprise at least one mandrel configuredto receive a roll of web material. Further, in some embodiments, thesecond face 28 of vertical section 20 c may comprise at least twomandrels, with each mandrel configured to receive a roll of webmaterial. Additionally, the second face 28 of vertical section 20 c maycomprise a splicer, similar to splicer 42, for example.

In an exemplary but non-limiting embodiment, a unique feature of theimproved unwind stand 10 is the use of a positionable roll graspingapparatus 150 which can be provided in the form of a robot 200 to move,relocate, and otherwise provide the various first and second webmaterials 46, 48 to the improved unwind stand 10. It would be understoodby one of skill in the art that robot 200 capabilities generally rangefrom simple repetitive point-to-point motions to complex motions thatcan be computer controlled and sequenced as part of the improved unwindstand 10. While positionable roll grasping apparatus 150 is provided inexemplary, non-limiting form herein as a robot 200 herein, one of skillin the art will appreciate that positionable roll grasping apparatus 150could be provided in other forms such as a series of connectedmechanical linkages, autonomous devices, and the like.

The robot 200 can be provided with an arm 210, a wrist subassembly 220and an end effector 230. An exemplary robot 200 could utilize aCartesian, cylindrical, polar, or revolute coordinate system tocoordinate motion relative to the improved unwind stand 10, the variousfirst and second web materials 46, 48, as well as the componentscooperatively associated thereto. One of skill in the art will recognizethat generally, three motion axes are employed to deliver the wristsubassembly 220 anywhere within the sphere of influence and threeadditional motion axes are employed for universal orientation of the endeffector 230. A drive system can be used for each motion axis, andwithout limitation the drive system can be electrical, hydraulic orpneumatic.

The robot 200 represented in the drawings consists of a mount 205, arocker 215, an extension arm 210, a wrist subassembly 220, as well as anend effector (also called a robot hand) 230 and can be provided with asmany as six or seven rotary axes. Alternatively, the robot 200 can bearranged in any position, whereby it is, for example, mounted to asupport, suspended at a portal, or can be attached to the frame 12. Theaxes are different with respect to the swinging and rotating axes,whereby the swinging axes in the robot 200 run crosswise to theextension of the robot 200 structure, and as a rule, horizontally. Theswinging angles are for the most part also limited. The rotational axesgenerally extend lengthwise to the respective robot structure or in thevertical plane. They permit as a rule greater rotational angles than theswinging axes. Further, rocker 215 can rotate around one or severalaxes.

Robot hand 230 can be constructed with respect to the kinematicsrequired to move convolutely wound rolls of web materials 46, 48 from afirst location to a second location. This may require moving the woundweb materials 46, 48 from a first location where the wound web materialsare stored to a second location that places the web materials proximateto, or in contacting engagement with frame 12, any of the mandrels 40a-40 v, or placing the web material comprising wound web materials 46,48 proximate to or in contacting engagement with, first, second, orthird splicers 42, 44, 38. For that matter, robot hand 230 can movewound web materials 46, 48 into any position or location that providesthe wound web material 46, 48 in the most efficacious position requiredto manufacture the articles envisioned.

Additionally, it is envisioned that robot hand 230 can be constructedwith respect to the kinematics required to remove the cores upon whichthe convolutely wound rolls of web materials 46, 48 are wound about fromcontacting engagement with any of the mandrels 40 a-40 v disposed uponframe 12. It is also envisioned that robot hand 230 can be provided as acentrally constructed articulating hand. This can provide the robot hand230 with the three continuous and interlaced axes of rotation(movement). This may require providing as many drive shafts axes thatextend inside the housing of extension arm 210. Each drive shaft can bedirectly attached to a respective motor with cardan links. Such a robot200 can facilitate the placement of sequential robots 200 arrangeddirectly next to one another with minimal distance and an ability tooperate separately without mutually hindering each other.

Additionally, it is envisioned that robot 200 and/or robot hand 230 canautomatically and/or autonomously determine any characteristic of a rollof web material such as the diameter of a roll of web material (e.g.,first web material 46), the diameter of a core region of a roll of webmaterial, the type of material comprising a roll of web material, aphysical characteristic of a roll of web material, or the like throughcomputer control or programming as would be available to one of skill inthe art. It is believed that such a determination could be beneficial inallowing the robot 200 to automatically and/or autonomously select anappropriate end effector 230 provided from a selection of available endeffectors 230. By way of non-limiting example, if the roll graspingapparatus 150 provided as robot 200 (or any ancillary component of rollgrasping apparatus 150) determines that a particular roll of webmaterial (e.g., first web material 46) has a diameter of 1 meter and acore diameter centrally disposed thereto has a diameter of 10 cm, anycontrol software, programming, or other PLC code could direct the robot200 to obtain an appropriately sized end effector 230 from a store ofend effectors 230. Alternatively, if robot 200 has a particular endeffector 250 disposed thereon and the control software, programming, orother PLC code determines that an end effector 250 disposed upon robot200 is incorrectly sized for the roll of web material, the controlsoftware, programming, or other PLC code could direct the robot toreturn the end effector 250 currently disposed thereon to a store of endeffectors 250 and select a new and/or appropriate end effector 250 forthe particular roll of web material. It is believed that such an abilityto change end effectors 250 ‘on-the-fly’ would necessarily increase theflexibility of a manufacturing process as well as decrease the amount oftime needed to change production of articles from one type requiring onetype of web material to another.

More particularly, as shown in FIG. 1, a six-axis industrial electricrobot 200 which is illustrative of a wide variety of robots that can beoperated in accordance with the principles of the present disclosure. Anexemplary robot 200 suitable for use with the present disclosure aspositionable roll grasping apparatus 150 is the model KR180L availablefrom Kuka Robotics. By way of non-limiting example, the model KR180L hasa 50-60 Kg payload capacity. The Model KR210L has an 80-90 Kg payloadcapacity and the model KR240L having a payload capacity of 110-120 Kgcan also be suitable for use. Such robots 200 can be particularly suitedfor precise, repetitive tasks.

In a preferred embodiment, positionable roll grasping apparatus 150(provided as robot 200) is provided in a configuration that is not inconnective engagement with frame 12. In other words, positionable rollgrasping apparatus 150 (provided as robot 200) can be provided with asupport assembly for mount 205 that is not physically attached to frame12, but is still capable of providing first and second web materials 46,48 in cooperative and connective engagement with any of the componentsof the improved unwind stand 10. This can include frame 12, first and/orsecond splicers 42, 44, mandrels 40 a-40 v, first and/or second dancers50, 52, first and second metering rolls, or any of the mandrels 40 andidler rollers disposed upon frame 12. Each axis of motion of robot 200can be generated by a brush type DC electric motor, with axis positionfeedback generated by incremental encoders. By way of example only,robot 200 and the wrist subassembly 220 can be provided with any numberof articulations, including an up/down rotation, a left/right rotation,a third motion, up and down elbow and shoulder rotations, and aleft/right arm rotation on the base of robot 200.

As would be understood by one of skill in the art, control software cansuitably operate the positionable roll grasping apparatus 150 (providedas robot 200) by incorporating absolute position feedback. A suitablerobot 200 control scheme can utilize a digital servo control. Forexample, each robot 200 can be operated with a torque control loop. Aposition control loop can be connected to a velocity control loop whichin turn can drive the torque control loop. A feed-forward accelerationcontrol loop that is responsive to an acceleration command as well asarm and load inertia sensors can be directly coupled to the input of thetorque control loop. Additionally, the robot 200, arm 210, rocker 215,wrist subassembly 220, and end effector (hand) 230 can be operated bythe control loop in accordance with a robot program through a stream ofprogram position commands applied to the position control loop. In anyregard, it can be preferable to implement such a control loop as adigital control.

A preferred control loop arrangement could provide position and velocitycontrol loops and to be parallel fed to the input of a torque controlloop. Velocity commands can be generated from position commands. Inturn, feed-forward acceleration commands can be generated from thevelocity commands. Computed inertia (arm 210, rocker 215, wristsubassembly 220, end effector 230, and the applied load) can bemultiplied against the acceleration command in the feed-forwardacceleration control loop.

A velocity command generator can interpolate velocity commands whichcorrespond with the velocity feedback sampling rate in a velocityfeedback path. Similarly, in a position control loop, an interpolatorcan generate position commands in correspondence with a feedback path.Velocity error can be generated by a summer with gain applied by a loop.Similarly, a position error can be generated by a summer. Velocity andposition errors and feed-forward acceleration command can be summed in asummer. Gain can be applied to generate a torque command that is appliedto the input of a torque control loop. The torque error can generated ina summer by summing the torque command (motor current command) withcurrent feedback and applying a torque loop gain to the torque error andoutput commands (motor voltage commands) that supplies the motor drivecurrent for robot 200 joint operation.

It is believed that end effector (robot hand) 230 can be provided with aunique device that provides for the ability to transfer convolutelywound rolls of web materials without the need for compressional forcesapplied to the external convolutions of the wound web materials.

Because of the compressible nature of the web materials, it is quitecommon for parent rolls to become out-of-round. Not only the soft natureof the web material, but also the physical size of the rolls, the lengthof time during which the rolls are stored, how the rolls are stored(e.g., on their end or on their side), and the fact that ‘roll grabbers’commonly used to transport these rolls clamp the roll generally aboutthe circumference all can contribute to this problem. As a result, bythe time many rolls are placed on an unwind stand for converting, theyhave changed from the desired cylindrical shape to an ‘other-than-round’(e.g., out-of-round) shape.

In extreme cases, rolls can become oblong, assume an ‘egg-like’ shape,or even resemble a flat tire. But, even when the roll is only slightlyout-of-round, there are considerable problems. In an ideal case, asmaterial is removed from a completely round, convolutely wound roll, thefeed-rate, web velocity, and tension will generally be consistent.However, process disturbances such as the feed-rate variability, webvelocity variability, and tension variability for an out-of-round,convolutely wound roll, caused by the shape changes created by thestorage and handling of rolls, will likely vary the material removalfrom the ideal web speed of a completely round roll depending upon theposition and/or radius at the web takeoff point at any moment in time.

If the rotational speed of the roll remains substantially constant, thefeed-rate, web velocity, and tension of the web material coming off ofan out-of-round roll will vary during any particular rotational cycle.Naturally, this depends upon the degree to which the roll isout-of-round. Since the paper converting equipment downstream of theunwind stand is generally designed to operate based upon the assumptionthat the feed-rate, web velocity, and tension of web material coming offof a rotating roll is generally consistent with the driving speed of theroll, web velocity, and/or tension spikes, and/or slackening during theunwinding process can cause significant problems. With an out-of-roundroll, such process disturbances cause the instantaneous feed-rate, webvelocity, and/or tension of the web material to be dependent upon therelationship at any point in time of the radius at the drive point andthe radius at the web takeoff point.

Clearly, there is a need to overcome this problem of causingout-of-round convolutely wound rolls of web material. Particularly,out-of-round rolls create variable web feed rates and corresponding webtension spikes and web tension slackening that have required that theunwind stand and associated paper converting equipment operatingdownstream thereof be run at a slower speed. In many instances thiscreates an adverse impact on manufacturing efficiency. Providing an endeffector 230 as discussed herein can obviate these aforementioneddrawbacks.

FIGS. 11-13 provide different perspective, planar, and sectional viewsof a suitable end effector 230. By non-limiting example, end effector230 is provided as a mandrel 300 having a plurality of elongate mandrelarms 310 disposed radially about the longitudinal axis 340 of mandrel300 and extending from mandrel shaft 320. Each mandrel arm 310 isprovided with at least one expansion element 330, and in most cases aplurality of expansion elements 330 disposed upon the outer surfacethereof. In principle, mandrel 300 is inserted into the hollow core areaof a convolutley wound material. The associated expansion elements 330associated with each mandrel arm 310 are then expanded radially awayfrom longitudinal axis 340. The outward expansion of the expansionelements 310 is limited by the diameter of the hollow core area of theconvolutely wound web material. Upon proper expansion of the expansionelements 310 against the hollow core of the convolutely wound webmaterial, a compression fit is realized that effectively provides theend effector 230 having the convolutely wound web material attachedthereto to freely move about and position the roll of convolutely woundweb material be positioned as may be required.

As depicted, mandrel 300 is provided with three mandrel arms 310arranged triangularly about longitudinal axis 340. Naturally, one ofskill in the art could provide a mandrel 300 with any number of mandrelarms 310 disposed as required about longitudinal axis 340. For example,one of skill in the art could provide only two mandrel arms 310 or evenfour mandrel arms 310.

One surprising aspect of providing mandrel 300 as a plurality of mandrelarms 310 is the ability to interleave a pair of mandrels 300. In otherwords, the mandrels arms 310 of opposed mandrels 300 can be disposed inan adjoining relationship so that the mandrel arms 310 of interlacedmandrels 300 are disposed radially and cooperatively about longitudinalaxis 340 and in cooperative engagement with each other. A surprisingbenefit of such interleaving is the ability to effectively transfer aconvolutley wound roll of web material disposed and locked upon a firstmandrel 300 to be transferred to a second mandrel 300 upon theinter-engagement of the mandrel arms 310 of a first mandrel 300 and themandrel arms 310 of a second mandrel 300.

As shown in FIGS. 14-15, opposed mandrels 300 a, 300 b and theirrespective mandrel arms 310 a, 310 b can be positioned into aninterengageable, opposing, interlocking fashion. Such interengageable,opposing, interlocking orientation can allow for the mandrel arms 310 ato be disposed adjacent mandrel arms 310 about longitudinal axis 340when mandrel 300 a is positioned coextensively with mandrel 300 b.

As shown in FIG. 15, each of the mandrel arms 310 b of mandrel 310 b canbe positioned into the region disposed between adjacent mandrel arms 310a of mandrel 300. Thus, if a convolutely wound roll of web material weredisposed upon mandrel 300 b so that it was disposed about the horizontalaxis 340 b and in contacting and locking engagement with expansionelements 330 b disposed within each mandrel arm 310 a, the mandrel arms310 b of mandrel 300 b could be interlaced with the mandrel arms 310 aof mandrel 300 a so that a designated mandrel arm 310 b is disposedbetween two adjacent mandrel arms 310 a of mandrel 300 a. If theexpansion elements 330 a disposed upon the respective mandrel arms 310 aof mandrel 300 a are kept in an un-expanded condition, both mandrel 300a and mandrel 300 b and the associated mandrel arms 310 a, 310 b can becoextensively disposed within the core of the convolutley wound webmaterial.

Thus, it would be possible during this coextensive and condition ofinterlocking engagement to expand the respective expansion elements 330a of mandrel 300 a and contract the respective expansion elements 330 bof mandrel 300 b. This would clearly and effectively provide for thetransfer of the roll of convolutley wound web material from mandrel 300b to mandrel 300 a.

It is believed that the respective expansion elements 330 can beexpanded and contracted though the use of appropriate valving and fluidsupply. Suitable fluids could be provided as a hydraulic control systemor an air control system. In certain cases, it may be suitable toprovide valves that can control and/or direct the flow of fluid tocontrol a particular expansion element 330 or plurality of expansionelements 330 as may be required by the user. In any regard, it ispreferred that the expansion elements 330 be expandable to the point ofcontacting engagement with the material defining the outside of thehollow core of the convolutley wound web material. The amount ofcontacting engagement should be sufficient to allow for the mandrel 300provided as an end effector 230 of robot 200 or provided as a mandrel 40disposed upon frame 12 of unwind stand 10 to allow the end effector 230or mandrel 40 to effectively position or unwind the roll of convolutelywound web material without loss of control of the convolutely wound webmaterial.

Another embodiment of the improved unwind stand 10 a is illustrated inFIG. 8. The improved unwind stand 10 a is provided with a frame 12 a.The frame 12 a includes various components, such as structural supportsand plates. As shown, the improved unwind stand 10 a may have aplurality of faces, including a first face 26 a and a second face 28 a.A cavity 30 a may be defined intermediate the first face 26 a and thesecond face 28 a.

The improved unwind stand 10 a may comprise a plurality of mandrels 40g, 40 h, 40 i, 40 j, 40 k, 40 l extending from a face of the improvedunwind stand 10 a, such as the first face 26 a. The mandrels 40 g, 40 h,40 i, 40 j, 40 k, 40 l may extend generally perpendicular to the firstface 26 a, or may be positioned at any other suitable angle. In oneembodiment, the improved unwind stand 10 a includes a first splicer 42 aand a second splicer 44 a. The first splicer 42 a and the second splicer44 a can be positioned on the improved unwind stand 10 a in any suitablelocation, such as above a given pair of mandrels 40 g, 40 h, 40 i, 40 j,40 k, 40 l. As illustrated in FIG. 8, the first splicer 42 a may beconfigured to receive a web material 48 a. Similarly, the second splicer44 a may be configured to receive a web material 46 a and a web material48 a.

The improved unwind stand 10 may further comprise a first lattice 62 adisposed above the mandrel pair 40 g/40 h. The first lattice 62 a maycomprise a plurality of rollers 64 a and a complimentary plurality ofrollers 66 a mounted to the frame 12 a. The number of rollers 64 a, 66 ain the first lattice 62 a may vary depending on the type of web materialbeing fed through the first lattice 62 a and the feed speed of the webmaterial 46 a, 48 a. The second lattice 72 a may similarly comprise aplurality of rollers 74 a and a plurality of rollers 76 a mounted to theframe 12 a disposed above mandrel pair 40 i/40 j. The number of rollersin the first lattice 62 a may differ from the number of rollers in thesecond lattice 72 a, as the number of rollers used is based oncharacteristics of the web material being fed through the lattices 62 a,72 a, such as web material 46 a, 48 a.

In one embodiment, a roll 104 a of the second web material 48 a maybemounted on the mandrel 40 h. The web material 48 a may be unwound fromthe roll 104 a and fed into and pass through the splicer 42 a. Oncepassing through the splicer 42 a, the web material 48 a may enter thefirst lattice 62 a. As illustrated in FIG. 8, the web material 48 a maybe looped over a roller 66 a and then extend to a roller 64 a. The webmaterial 48 a may then extend between a series of complimentary rollersin the first lattice 62 a thereby forming a “festoon.” The web material48 a may be directed toward downstream equipment.

First and second web materials 46 a, 48 a can be provided to theimproved unwind stand 10 a through means known to those of skill in theart. For example, as shown, first and second web materials 46 a, 48 acan be provided to the improved unwind stand 10 a through the use ofcarts (not shown). By way of example only, the carts can be providedwith a quantity of convolutely wound rolls of web material suitable foruse as first and second web materials 46 a, 48 a.

Further, the improved unwind stand 10 a may include mandrels on otherfaces that are configured to receive rolls of web material. In oneembodiment, the second face 28 a may comprise a set of mandrels. Rollsof web material may be mounted on these mandrels and during operationdownstream equipment may be continuously fed with web material from atleast one of the rolls. It is to be appreciated that in some embodimentsthe second face 28 a may comprise at least one mandrel configured toreceive a roll of web material. Further, in some embodiments, the secondface 28 a may comprise at least two mandrels, with each mandrelconfigured to receive a roll of web material. Additionally, the secondface 28 a may comprise a splicer, similar to splicer 42 a, for example.

A robot 200 a can provide the various first and second web materials 46a, 48 a to the improved unwind stand 10 a. A six-axis industrialelectric robot 200 a was found suitable. In a preferred embodiment, arobot 200 a is provided in a configuration that is cooperativelydisposed upon 12 a. In other words, robot 200 a can be provided with asupport assembly that is physically attached to frame 12 a and is stillcapable of loading, unloading, and/or unwinding the first and second webmaterials 46 a, 48 a in cooperative and connective engagement with anyof the components of the improved unwind stand 10 a. This can includeframe 12 a, first and/or second splicers 42 a, 44 a, mandrels 40 g, 40h, 40 i, 40 j, 40 k, 40 l first and/or second dancers 50 a, 52 a, firstand second metering rolls, or any of the mandrels 40 and idler rollersdisposed upon frame 12 a.

Yet another embodiment of the improved unwind stand 10 b is illustratedin FIG. 9. The improved unwind stand 10 b is provided with a frame 12 b.The frame 12 b includes various components, such as structural supportsand plates. As shown, the improved unwind stand 10 b may have aplurality of faces, including a first face 26 b and a second face 28 b.

The improved unwind stand 10 b may comprise a plurality of mandrels 40m, 40 n, 40 o, 40 p, 40 q, 40 r extending from a face of the improvedunwind stand 10 b, such as the first face 26 b. The mandrels 40 m, 40 n,40 o, 40 p, 40 q, 40 r may extend generally perpendicular to the firstface 26 b, or may be positioned at any other suitable angle. As shown,the improved unwind stand 10 b preferably includes a first splicer 42 band a second splicer 44 b. The first splicer 42 b and the second splicer44 b can be positioned on the improved unwind stand 10 b in any suitablelocation, such as above a given pair of mandrels 40 m, 40 n, 40 o, 40 p,40 q, 40 r. As illustrated, the first splicer 42 b may be configured toreceive web materials 46 b, 48 b. Similarly, the second splicer 44 b maybe configured to receive a web material 46 b and a web material 48 b.

The improved unwind stand 10 b may further comprise a first lattice 62 bdisposed below the mandrel pair 40 m/40 n. The first lattice 62 b maycomprise a plurality of complimentary plurality of rollers. The secondlattice 72 b may similarly comprise a plurality of complementary rollersmounted to the frame 12 b disposed above mandrel pair 40 o/40 p.

Web material 48 b may be unwound fed into and pass through the splicer42 b. Once passing through the splicer 42 b, the web material 48 b mayenter the first lattice 62 b to form a festoon. The web material 48 bmay then be directed toward downstream equipment.

First and second web materials 46 b, 48 b can be provided to theimproved unwind stand 10 b through the use of carts 110 b. By way ofexample only, the carts can be provided with a quantity of convolutelywound rolls of web material suitable for use as first and second webmaterials 46 b, 48 b.

A robot 200 b used for positionable roll grasping apparatus 150 canprovide the various first and second web materials 46 b, 48 b to theimproved unwind stand 10 b. In the preferred embodiment shown in FIG. 9,robot 200 b is provided in a configuration that is cooperativelydisposed upon 12 b. In other words, positionable roll grasping apparatus150 (provided as robot 200 b) is not physically attached to frame 12 band is still capable of providing first and second web materials 46 b,48 b in cooperative and connective engagement with any of the componentsof the improved unwind stand 10 b. However, one of skill in the artwould recognize that robot 200 b could be physically attached to frame12 b and be capable of providing first and second web materials 46 b, 48b in cooperative and connective engagement with any of the components ofthe improved unwind stand 10 b.

Yet another embodiment of the improved unwind stand 10 b is illustratedin FIG. 10. The improved unwind stand 10 b comprising a plurality ofmandrels 40 s, 40 t, 40 v (only shown) extending from a face of theimproved unwind stand 10 c. As shown, the improved unwind stand 10 cpreferably includes a first splicer 42 c and a second splicer 44 c. Thefirst splicer 42 c and the second splicer 44 c can be positioned on theimproved unwind stand 10 b in any suitable location, such as adjacent agiven pair of mandrels 40 s/40 t. As illustrated, the first splicer 42 bmay be configured to receive web materials 46 c, 48 c. Similarly, thesecond splicer 44 c may be configured to receive a web material 46 c anda web material 48 c.

The improved unwind stand 10 c may further comprise a first lattice 62 cdisposed adjacent the mandrel pair 40 s/40 t. The first lattice 62 c maycomprise a plurality of complimentary plurality of rollers 64 c, 66 c.The second lattice 72 c may similarly comprise a plurality ofcomplementary rollers disposed adjacent a second mandrel pair (notshown)/40 v.

Web material 48 c may be unwound fed into and pass through the splicer42 c. Once passing through the splicer 42 c, the web material 48 c mayenter the first lattice 62 c to form the festoon. The web material 48 cmay then be directed toward downstream equipment. The first and secondweb materials 46 c, 48 c can be provided to the improved unwind stand 10c through the use of carts 110 c. By way of example only, the carts canbe provided with a quantity of convolutely wound rolls of web materialsuitable for use as first and second web materials 46 c, 48 c.

A robot 200 c can provide the various first and second web materials 46c, 48 c to the improved unwind stand 10 c. In the preferred embodimentshown in FIG. 10, robot 200 c and the associated arm 210C is provided ina configuration that is cooperatively disassociated with frame 12 c butis integral with the equipment disposed thereon. In other words, robot200 c is physically unattached to frame 12 c and is still capable ofproviding first and second web materials 46 c, 48 c in cooperative andconnective engagement with any of the components of the improved unwindstand 10 c.

FIGS. 16-20 depict an exemplary use of the unwind stand 10 of thepresent description that can provide an overall discussion of a methodto deliver a plurality of web materials to downstream manufacturingequipment. In particular, FIGS. 15-19 depict an exemplary method toprovide rolls of convolutely wound web materials to an exemplary unwindstand 10 of the present disclosure using the components describedherein. As shown, positionable roll grasping apparatus 150 (provided asrobot 200) is not in direct contacting engagement with unwind stand 10(i.e., robot 200 is positioned external to unwind stand 10).

FIG. 16 provides for an exemplary positionable roll grasping apparatus150 (provided as robot 200) having an end effector 230 in the form ofmandrel 300 having mandrel shafts 320 assume contacting engagement withthe hollow core portion of a second web material 48. As can be seen afirst web material 46 is engaged with a mandrel 300 having mandrelshafts 320 disposed upon unwind stand 10. First web material 46 is beingconvolutley unwound from first web material 46 and is directed toward adownstream manufacturing operation.

FIG. 17 provides an exemplary perspective view of positionable rollgrasping apparatus 150 (provided as robot 200) transporting second webmaterial 48 into eventual contacting and mating engagement with an emptymandrel 300 disposed upon unwind stand 10. As robot 200 is positioningthe second web material 48, first web material 46 is being unwound toprovide web material to a downstream manufacturing operation.

FIG. 18 provides an exemplary perspective view of positionable rollgrasping apparatus 150 (provided as robot 200) disposing second webmaterial 48 into contacting and mating engagement with an empty mandrel300 disposed upon unwind stand 10. Here, the mandrel arms 310 of mandrel300 forming end effector 230 of robot 200, as described herein, arealigning to provide cooperative and interleaving engagement with themandrel arms 310 of mandrel 300 disposed upon frame 12 of unwind stand10 with the use of position controllers as would be done and known toone of skill in the art. In other words, the mandrel arms 310 inarrested contact with second web material 48 are aligning with theinterstitial spaces disposed between mandrel arms 310 of mandrel 300disposed upon frame 12 of unwind stand 10. As second web material 48 isbrought into proximate contact with the mandrel 300 disposed upon frame12 of unwind stand 10, second web material is positioned relative toframe 12 and or any processing equipment disposed or intended to bedisposed thereupon.

FIGS. 19-20 provides exemplary perspective views of positionable rollgrasping apparatus 150 (provided as robot 200) disengaging end effector230 comprising mandrel 300 from second web material 48 which is now incontacting and mating engagement with the mandrel 300 disposed uponframe 12 of unwind stand 10. At this point, robot 200 can be providedwith a new or different task relative to the production of materialsassociated with unwind stand 10.

All publications, patent applications, and issued patents mentionedherein are hereby incorporated in their entirety by reference. Citationof any reference is not an admission regarding any determination as toits availability as prior art to the claimed invention.

The dimensions and/or values disclosed herein are not to be understoodas being strictly limited to the exact numerical values recited.Instead, unless otherwise specified, each such dimension and/or value isintended to mean both the recited dimension and/or value and afunctionally equivalent range surrounding that dimension and/or value.For example, a dimension disclosed as “40 mm” is intended to mean “about40 mm”.

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A mandrel suitable for supporting and unwinding aconvolutely wound web material, a portion of said convolutely wound webmaterial forming a hollow core therein, said mandrel comprising: a. amandrel shaft having a longitudinal axis, said mandrel shaft beingcapable of rotating about said longitudinal axis; b. a plurality ofmandrel arms extending from said mandrel shaft, each of said mandrelarms being disposed and rotatable about said longitudinal axis; c. atleast one expansion element disposed upon a respective each of saidmandrel arms, said at least one expansion element being expandableradially away from said respective mandrel arm relative to saidlongitudinal axis; and, d. said core of said convolutely wound webmaterial being disposable about each of said mandrel arms, said at leastone expansion element being expandable into contacting and releasableengagement with said portion of said convolutely wound web materialforming said hollow core, said convolutely wound web material beingfixably and releasably disposed about each of said mandrel arms.
 2. Themandrel of claim 1 wherein each of said plurality of mandrel arms ispositioned orbitally and equidistant about said longitudinal axis. 3.The mandrel of claim 2 wherein said plurality of mandrel arms arecoextensively and cooperatively interengageable with a plurality ofmandrel arms extending from a second mandrel.
 4. The mandrel of claim 3wherein said convolutely wound web material is repositionable from saidplurality of arms extending from said mandrel shaft of said mandrel tosaid plurality of mandrel arms extending from said second mandrel. 5.The mandrel of claim 3 wherein said plurality of mandrel arms extendingfrom said second mandrel each have at least one expansion elementdisposed thereupon, said at least one expansion element disposed uponeach of said plurality of mandrel arms extending from second mandrelbeing expandable into contacting and releasable engagement with saidportion of said convolutely wound web material forming said hollow corewhen said hollow core is disposed thereabout.
 6. The mandrel of claim 5wherein said convolutley wound web material is transferrable from saidplurality of mandrel arms extending from said mandrel shaft of saidmandrel to said plurality of mandrel arms extending from said secondmandrel when said mandrel arms extending from said mandrel shaft of saidmandrel and said plurality of mandrel arms extending from said secondmandrel are cooperatively engaged.
 7. The mandrel of claim 6 whereinsaid convolutley wound web material is transferred from said pluralityof mandrel arms extending from said mandrel shaft of said mandrel tosaid plurality of mandrel arms extending from said second mandrel whensaid at least one expansion element disposed upon each of saidrespective mandrel arms of said mandrel contract radially away towardsaid respective mandrel arm relative to said longitudinal axis and saidat least one expansion element disposed upon each of said plurality ofmandrel arms extending from second mandrel expand into contacting andreleasable engagement with said portion of said convolutely wound webmaterial forming said hollow core when said mandrel arms extending fromsaid mandrel shaft of said mandrel and said plurality of mandrel armsextending from said second mandrel are cooperatively engaged.
 8. Themandrel of claim 1 wherein said mandrel is provided as an end effectorfor a robot.
 9. The mandrel of claim 1 wherein said mandrel is attachedto a frame forming an unwind stand for unwinding a convolutely wound webmaterial.
 10. An end effector for a robot, said end effector comprising:a. a mandrel shaft having a longitudinal axis, said mandrel shaft beingcapable of rotating about a longitudinal axis; b. a plurality of mandrelarms extending from said mandrel shaft, each of said mandrel arms beingdisposed and rotatable about said longitudinal axis; and, c. at leastone expansion element disposed upon a respective each of said mandrelarms, said at least one expansion element being expandable radially awayfrom said respective mandrel arm relative to said longitudinal axis. 11.The end effector of claim 10 wherein each of said plurality of mandrelarms is positioned orbitally and equidistant about said longitudinalaxis.
 12. The mandrel of claim 10 wherein said plurality of mandrel armsare coextensively and cooperatively interengageable with a second endeffector, said second end effector comprising: a. a second mandrel shafthaving a second longitudinal axis, said mandrel shaft being capable ofrotating about said second longitudinal axis; b. a second plurality ofmandrel arms extending from said second mandrel shaft, each of saidsecond plurality of mandrel arms being disposed and rotatable about saidsecond longitudinal axis; and, c. at least one second expansion elementdisposed upon a respective each of said second plurality of mandrelarms, said at least one second expansion element being expandableradially away from said respective mandrel arm of said second pluralityof mandrel arms relative to said second longitudinal axis; and d.wherein said end effector and said second end effector are cooperativelyinterengageable when said longitudinal axis and said second longitudinalaxis are collinear.
 13. The end effector of claim 12 wherein said secondend effector is a mandrel.
 14. The end effector of claim 13 wherein saidmandrel extends from a frame.
 15. The end effector of claim 14 wherein aconvolutley wound web material disposable about said plurality ofmandrel arms.
 16. The end effector of claim 15 wherein said convolutleywound web is repositionable from said end effector to said mandrel. 17.The end effector of claim 15 wherein said convolutley wound web materialis transferred from said end effector to said mandrel when said at leastone expansion element disposed upon each of said respective mandrel armsof said end effector contract radially away toward said respectivemandrel arm relative to said longitudinal axis and said second at leastone expansion element disposed upon each of said second plurality ofmandrel arms extending from second end effector expand into contactingand releasable engagement with a portion of said convolutely wound webmaterial forming a hollow core when said mandrel arms of said endeffector and said plurality of mandrel arms extending from said secondend effector are cooperatively engaged.
 18. A mandrel arm for a mandrel,said mandrel arm comprising at least one expansion element disposed upona surface of said mandrel arm, said at least one expansion element beingexpandable radially away from said surface.
 19. The mandrel arm of claim18 wherein a plurality of mandrel arms are operatively connected to amandrel shaft having a longitudinal axis, each of said plurality ofmandrel arms being disposed about and orbit about said longitudinalaxis.
 20. The mandrel arm of claim 18 wherein said mandrel arm is an endeffector operatively connected to device selected from the groupconsisting of robots, unwind stands, and combinations thereof.